Composite fan housing and method

ABSTRACT

A fan assembly, fan housing, and associated methods are shown. Configurations and methods are shown that include reinforcing layers over a seam of a housing, such as a composite housing. In one example, both an inside and an outside of a seam are reinforced.

TECHNICAL FIELD

Embodiments described herein generally relate to fan assemblies. Specific examples may include centrifugal fan housings and fan assemblies.

BACKGROUND

In some fan applications, it is desirable to use non-metallic components in a fan assembly. Examples include, but are not limited to, movement of air that may contain chemicals that are corrosive to metal, and fan applications where a light weight fan is desired. If there is a failure of a fan component, such as an impeller, it is desirable to contain any damaged parts within a fan housing. An improved fan assembly and methods that addresses at least these concerns are desired.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fan assembly in accordance with some embodiments of the invention.

FIG. 2 is a cross section of a portion of a fan housing in accordance with some embodiments of the invention.

FIG. 3 is a flow diagram of a method of forming a fan housing in accordance with some embodiments of the invention.

DESCRIPTION OF EMBODIMENTS

The following description and the drawings sufficiently illustrate specific embodiments to enable those skilled in the art to practice them. Other embodiments may incorporate structural, logical, electrical, process, and other changes. Portions and features of some embodiments may be included in, or substituted for, those of other embodiments. Embodiments set forth in the claims encompass all available equivalents of those claims.

FIG. 1 shows a fan assembly 100 according to an embodiment of the invention. The fan assembly 100 includes an impeller 102, an inlet 106, and an outlet 108. A mounting frame 104 is coupled to the assembly 100 to position the assembly within its associated ductwork or other location for movement of air, gas, or other fluids.

In the example shown, the fan assembly 100 is a centrifugal fan, although the invention is not so limited. Examples of the invention may also be used with axial impellers, and/or mixed flow impellers. Examples of the present invention may be used with any fan assembly using a housing with multiple portions where a seam is used to join two or more portions.

The fan assembly 100 of FIG. 1 shows a first housing portion 110 and a second housing portion 112 that are joined together at a seam 120. In the example shown, the first housing portion 110 and the second housing portion 112 are formed from a composite material. In one example, the composite material includes fiber glass. Other examples of composite materials include, but are not limited to, carbon fiber composites, resin and aramid composites such as Kevlar, or other fiber reinforced composites.

As noted above, in selected fan applications such as moving corrosive gasses, or applications where weight is a concern, multiple components of the fan assembly 100 may be formed from a composite material. In one example the impeller 102 may be formed from a composite material.

In one example composite portions may include multiple layers of composite material, for example multiple laminated composite fabrics, or chopped fiber reinforced layers, combinations of layers, etc. In one example, a metal layer or other non-composite material may be included within a stack of layers, with the final layer that will contact the fluid or gas being a non-corrosive layer. In one example one or more layers may include a non-reinforced polymer.

FIG. 2 shows a cross section of portions of a fan housing 200, such as the first portion 110, and the second portion 112 from FIG. 1. In FIG. 2, a first housing portion 202 and a second housing portion 204 are shown forming a seam 210. In the example shown, the first housing portion 202 and the second housing portion 204 include multiple layers. The housing portions 202, 204 shown in FIG. 2 include at least one woven roving layer 206 with an outer chopped gun roving layer 208. In the example shown, there are two woven roving layers 206 and both an inside and an outside of the fan housing portions 202, 204 are covered in a chopped gun roving layer 208. In the example shown, all composite materials include glass fiber reinforced materials, however, as noted above any number of different fiber choices are within the scope of the invention.

FIG. 2 shows the first housing portion 202 and the second housing portion 204 joined together at the seam 210 with an adhesive 214. One example of an acceptable adhesive 214 includes two part methacrylate adhesive.

FIG. 2 shows at least one reinforcing layer adhered over the seam 210 on an inside 200A of the housing 200. In the example shown, multiple reinforcing layers are adhered over the seam 210. FIG. 2 shows multiple woven roving layers 222 and a chopped strand mat layer 224 adhered over the seam 210 on an inside of the housing portions 202, 204. In the example shown, three woven roving layers 222 are first adhered over the seam 210, with a single chopped strand mat layer 224. Although this combination of multiple layers is used as an example one of ordinary skill in the art will recognize that various other combinations of one layer or multiple layers adhered over the seam 210 on an inside 200A of the housing 200 may be effective as well.

In use, the reinforcing layers, such as layers 222 and 224, strengthen the seam 210 and improve the structural integrity of the housing 200 as a whole. In this way, multiple housing portions such as first housing portion 202 and second housing portion 204 can be joined together in an improved seam that is stronger than a seam without reinforcement.

In one example, at least one second reinforcement layer is included to cover the seam 210 on an outside 200B of the housing 200. In FIG. 2, two layers of chopped strand mat 230 are shown covering the seam 210 on an outside 200B of the housing 200. Although two layers 230 are shown, one of ordinary skill in the art, having the benefit of the present disclosure, will recognize that one layer, or more than two layers may also be effective, depending on the design parameters of a specific fan assembly.

In the examples shown, both the first reinforcing layers, such as layers 222 and 224, and the second reinforcing layers 230 are glass fiber composite layers. As with the housing portions 202, 204 themselves, other fiber materials may be used for the reinforcing layers 222, 224, 230 without departing from the scope of the invention. As with the first reinforcing layers 222, 224, the addition of the second reinforcing layer or layers 230 strengthen the seam 210 and improves the structural integrity of the housing as a whole.

FIG. 2 further shows a mechanical fastener 234 clamping the seam 210 together on the outside of the housing. In the example shown, the mechanical fastener 234 not only passes through a portion of the first housing portion 202 and the second housing portion 204, but also passes through the second reinforcing layer or layers 230. In one example, the mechanical fastener 234 is further reinforced by adding an adhesive 236 within the hole that the mechanical fastener 234 passes through. In one example, the adhesive 236 includes two part methacrylate adhesive, similar to the adhesive 214 used between the first housing portion 202 and the second housing portion 204.

In the example of FIG. 2, a portion of the first housing portion 202 and the second housing portion 204 include extending portions 203 and 205 than extend away from the housing 200 to form an extending portion 212. In the example shown, the second reinforcing layer or layers 230 form a channel that covers the extending portion 212. In one example, the second reinforcing layer or layers 230 are adhered over the seam 210. In other examples, the second reinforcing layer or layers 230 are not adhered to the housing 200, but are instead placed over the seam 210 and held in place using the mechanical fastener 234.

In one example the seam 210 includes one or more wraps of poly strapping 232 that cover the exposed adhesive 214 prior to placement of the reinforcing layer or layers 230. In the example shown, the mechanical fastener 234 includes a bolt and a nut, although any number of mechanical fasteners are within the scope of the invention, including, but not limited to, rivets, screws, barbed fittings, etc.

Although the example seam 210 and the example fan assembly 100 show a single seam, the invention is not so limited. In other examples, multiple housing portions may be joined together using configurations described above to form a housing for a fan assembly.

FIG. 3 shows an example method of forming a fan housing. In operation 310, a seam is covered with a reinforcing layer adhered over the seam on an inside of the housing. In operation 312, an extending portion of the seam that extends away from an outside of the housing is covered with a reinforcing channel. In operation 314, the seam is clamped together using a number of mechanical fasteners on the outside of the housing.

To better illustrate the method and apparatuses disclosed herein, a non-limiting list of embodiments is provided here:

Example 1 includes a fan assembly. The fan assembly includes an impeller, a rotatable shaft coupled to a center of the impeller, and a housing covering at least a portion of the impeller. The housing including at least two housing portions joined together at a seam and a reinforcing layer adhered over the seam on an inside of the housing.

Example 2 includes the fan assembly of example 1, wherein the least two housing portions include composite material portions.

Example 3 includes the fan assembly of any one of examples 1-2, wherein the least two housing portions include fiberglass reinforced composite portions.

Example 4 includes the fan assembly of any one of examples 1-3, wherein the reinforcing layer includes multiple reinforcing layers.

Example 5 includes the fan assembly of any one of examples 1-4, wherein the multiple reinforcing layers includes both a woven fiber reinforced composite layer and random matted fiber reinforced composite layer.

Example 6 includes the fan assembly of any one of examples 1-5, wherein the at least two housing portions are adhered together along an extending portion of the two housing portions that extends away from an outside of the housing.

Example 7 includes a fan assembly, comprising an impeller, a rotatable shaft coupled to a center of the impeller and a housing covering at least a portion of the impeller. The housing includes at least two housing portions joined together at a seam, a first reinforcing layer adhered over the seam on an inside of the housing, and a second reinforcing layer covering the seam on an outside of the housing.

Example 8 includes the fan assembly of example 7, wherein the least two housing portions include composite material portions.

Example 9 includes the fan assembly of any one of examples 7-8, wherein the second reinforcing layer includes a fiber reinforced composite layer.

Example 10 includes the fan assembly of any one of examples 7-9, further including a number of mechanical fasteners that engage the two housing portions and the second reinforcing layer on the outside of the housing.

Example 11 includes the fan assembly of any one of examples 7-10, wherein the at least two housing portions are adhered together along an extending portion of the two housing portions that extends away from an outside of the housing.

Example 12 includes a fan assembly, comprising an impeller, a rotatable shaft coupled to a center of the impeller, and a housing covering at least a portion of the impeller. The housing includes at least two housing portions joined together at a seam, the seam including an extending portion of the two housing portions that extends away from an outside of the housing. The fan assembly also includes a reinforcing layer adhered over the seam on an inside of the housing, a reinforcing channel covering the extending portion of the seam, and a number of mechanical fasteners clamping the seam together on the outside of the housing.

Example 13 includes the fan assembly of example 12, wherein the at least two housing portions are adhered together at the seam.

Example 14 includes the fan assembly of any one of examples 12-13, wherein the number of mechanical fasteners are further adhered in place.

Example 15 includes the fan assembly of any one of examples 12-14, wherein the least two housing portions include composite material portions.

Example 16 includes the fan assembly of any one of examples 12-15, wherein the reinforcing layer includes one or more fiber reinforced composite layers.

Example 17 includes the fan assembly of any one of examples 12-16, wherein the reinforcing channel includes one or more fiber reinforced composite layers.

Example 18 includes a method of forming a fan housing, comprising covering a seam with a reinforcing layer adhered over the seam on an inside of the housing, covering an extending portion of the seam that extends away from an outside of the housing with a reinforcing channel, and clamping the seam together using a number of mechanical fasteners on the outside of the housing.

Example 19 includes the method of example 18, further including adhering the extending portion of the seam together.

Example 20 includes the method of any one of examples 18-19, wherein covering a seam with a reinforcing layer and covering an extending portion of the seam include covering with one or more fiber reinforced composite layers.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. 

1. A fan assembly, comprising: an impeller; a rotatable shaft coupled to a center of the impeller; and a housing covering at least a portion of the impeller, the housing including: at least two housing portions joined together at a seam; and a reinforcing layer adhered over the seam on an inside of the housing.
 2. The fan assembly of claim 1, wherein the least two housing portions include composite material portions.
 3. The fan assembly of claim 2, wherein the least two housing portions include fiberglass reinforced composite portions.
 4. The fan assembly of claim 1, wherein the reinforcing layer includes multiple reinforcing layers.
 5. The fan assembly of claim 4, wherein the multiple reinforcing layers includes both a woven fiber reinforced composite layer and random matted fiber reinforced composite layer.
 6. The fan assembly of claim 1, wherein the at least two housing portions are adhered together along an extending portion of the two housing portions that extends away from an outside of the housing.
 7. A fan assembly, comprising: an impeller; a rotatable shaft coupled to a center of the impeller; and a housing covering at least a portion of the impeller, the housing including: at least two housing portions joined together at a seam; a first reinforcing layer adhered over the seam on an inside of the housing; and a second reinforcing layer covering the seam on an outside of the housing.
 8. The fan assembly of claim 7, wherein the least two housing portions include composite material portions.
 9. The fan assembly of claim 7, wherein the second reinforcing layer includes a fiber reinforced composite layer.
 10. The fan assembly of claim 7, further including a number of mechanical fasteners that engage the two housing portions and the second reinforcing layer on the outside of the housing.
 11. The fan assembly of claim 7, wherein the at least two housing portions are adhered together along an extending portion of the two housing portions that extends away from an outside of the housing.
 12. A fan assembly, comprising: an impeller; a rotatable shaft coupled to a center of the impeller; and a housing covering at least a portion of the impeller, the housing including: at least two housing portions joined together at a seam, the seam including an extending portion of the two housing portions that extends away from an outside of the housing; a reinforcing layer adhered over the seam on an inside of the housing; and a reinforcing channel covering the extending portion of the seam; and a number of mechanical fasteners clamping the seam together on the outside of the housing.
 13. The fan assembly of claim 12, wherein the at least two housing portions are adhered together at the seam.
 14. The fan assembly of claim 13, wherein the number of mechanical fasteners are further adhered in place.
 15. The fan assembly of claim 12, wherein the least two housing portions include composite material portions.
 16. The fan assembly of claim 12, wherein the reinforcing layer includes one or more fiber reinforced composite layers.
 17. The fan assembly of claim 12, wherein the reinforcing channel includes one or more fiber reinforced composite layers.
 18. A method of forming a fan housing, comprising: covering a seam with a reinforcing layer adhered over the seam on an inside of the housing; covering an extending portion of the seam that extends away from an outside of the housing with a reinforcing channel; and clamping the seam together using a number of mechanical fasteners on the outside of the housing.
 19. The method of claim 18, further including adhering the extending portion of the seam together.
 20. The method of claim 18, wherein covering a seam with a reinforcing layer and covering an extending portion of the seam include covering with one or more fiber reinforced composite layers. 